Abstract: A reinforced casting assembly formed of ferrous metal for use with hot chamber die casting including a gooseneck, nozzle seat and nozzle. Reinforcing members are used to reinforce the casting. The preferred embodiment is reinforcing the gooseneck as this is where most failures created by the high internal pressure of hot melt die casting occur. The reinforcing members generally are made of steel wire such as a solid or braided wire.

Abstract: An injection molding machine having a simple structure and adapted to quickly operate for injection molding without taking in air bubbles is provided. The injection molding machine comprises a plunger and a nozzle for injecting the molten metal fed from the plunger into a metal mold. The plunger has a cylinder section with a through hole bored through an upper portion of its lateral wall for introducing the molten metal, and a piston for slidingly reciprocating within the cylinder section. A communication hole is bored through the piston and communicates with the through hole at a predetermined position. The communication hole runs from the lateral wall of the piston through the inside thereof and has a non-return valve arranged therein to allow only a flow from the lateral wall of the piston.

Abstract: A sealing and guiding device for the injection piston (3) of a hot chamber pump for corrosive alloys made up of a body (1) in which a chamber (6) and an injection cavity (2) therebelow are formed, wherein the piston (3) slides with a vertical reciprocating motion (V), includes a bush (8), having an outer diameter smaller than said chamber (6), interposed between centering members housed in the chamber (6) and made coaxial with the chamber (6) and with the piston (3) by a pair of opposite surfaces of revolution (12, 13) formed on said centering members, the upper surface (13) and the relevant centering member performing a pressure-tight sealing. The outer lateral surface (15) of the bush (8) is in communication with the injection cavity (2) whereas the upper side of the bush (8) is in communication with the crucible and immersed therein at a depth (L), measured from the lowest level (23) reachable by the molten alloy, which is greater than the maximum travel (C) of the piston (3).

Abstract: In order to improve the compression operation and to produce better products with thin-walled castings, the invention calls for the compression operation to be divided into three phases and controlled by high-dynamic continuous-operation valves which have very short switching times and are actuated by a control device. Fitted in the hot-chamber die-casting machine for this purpose is a metal sensor which is disposed in a die relief leading from the rising bore in the casting container into the mould.

Abstract: A machine for producing metal die castings is disclosed and comprises a crucible that incorporates an injection pump assembly which is mounted in such a way as to clear the upper access of the crucible to facilitate cover sealing and removing. The crucible is located in a furnace and is reciprocable to move the injection barrel and nozzle to and from a mold. The injection barrel is immersed in the crucible beneath the level of the molten metal to enhance heat transfer between the barrel and injected metal. The separate plunger and shot assemblies are located in the pump body in a "V" configuration so that maintenance of these units can be carried out without exposing the top of the furnace to the atmosphere.

Abstract: In the casting of metal alloys with low melting temperatures, an improved control system for lowering an injection piston in an injection cylinder is provided to avoid porosity occurring in castings. There is a fluid operated drive cylinder with a drive piston connected to the injection piston. A transducer is linked to the injection piston to provide an indication of location, and a controller compares the position of the injection piston with a predetermined time/distance profile and produces an injection stroke signal which is used to control the drive cylinder and ensure the injection piston follows the time/distance profile.

Abstract: A metal casting process for producing melt-out metal cores and the like made of metal alloys with low melting temperatures achieves a casting with uniform density, high quality finish and a fine grain structure. The process and apparatus do not require the pre-pressurization of a charging cylinder and permit closed dies to be used. The apparatus comprises a molten metal alloy tank, a cylinder in the tank having at its base a connection to a passageway leading through the tank to a die located outside the tank. A valve is provided in the passageway, located in the tank having a first position where the passageway to the die is open and a second position where the passageway to the die is closed. In the second position, a valve port provides a connection from the cylinder to the molten metal alloy in the tank.

Abstract: An improved valve mechanism for casting metal alloys with low melting temperatures provides two valves in a single assembly inside an alloy tank. The valves being in the tank reduces the formation of oxides which can occur in air and tends to reduce leaks. The apparatus comprises a tank adapted to contain molten metal alloys, a cylinder in the tank having at its base a connection to an injection passageway which leads through the tank to a die located outside the tank. A piston reciprocates in the tank which allows molten metal alloy to be drawn into the cylinder and forced through the passageway to the die. A control system for the piston controls accurately the speed of the piston in the cylinder when the molten metal alloy is fed to the die.

Abstract: A casting apparatus comprising a crucible furnace for containing a molten metal, a die assembly defining a die cavity having a casting volume for producing a die casting by forcing molten metal from the crucible furnace thereinto, an injection sleeve having a feed slot located therein, wherein the injection sleeve is vertically oriented for supplying the molten metal upwardly towards the die cavity, a feed block proximate to the injection sleeve and comprising a curved passage therein one end of which communicates with the feed slot, a feed pipe connected to the other end of the curved passage for providing fluid communication between the crucible furnace and the curved passage, feeder means for feeding the molten metal from the crucible furnace, through the feed pipe and the curved passage in the feed block, and through the feed slot into the injection sleeve.

Abstract: A die casting system comprises a machine of the balanced, dual movement type wherein the part is cast and trimmed without any lateral movement. Both halves of the molds or dies are moved equal distances to and from the part plane. The machine incorporates a system of metal injection on the mold parting line with a runner-drain provision; provision for supporting the part at a plurality of points after the die opening; hydraulic fluid volumetric flow reduction; various nozzle configuration options and a heat transfer system for the dies. In addition, a part trimming machine is disclosed together with a cable transfer for moving the part from the casting machine to the trimming machine.

Abstract: Apparatus and method for injecting molten lead from a reservoir into a die mold cavity formed about an aperture in the wall of a plastic battery for casting lead-alloy battery terminal connectors. Batteries are positioned adjacent the molten lead reservoir of the apparatus and mold portions move together to hold the battery containers in a clamp-like action. Molten lead is die cast under pressure into the mold cavity in which a stainless steel threaded nut is positioned. The lead is forced through a heated chamber into a portion of the mold which may be water cooled. The mold is designed to allow venting of gases, thereby eliminating porosity; and the apparatus is designed to provide casting which is free of jagged projections in the sprue hole.

Abstract: A die casting machine has a frame with a base plate pivotally mounted thereon and supporting a furnace pot. A die assembly is mounted on the front face of the base plate and a double locking toggle arrangement is used to open and close the dies. The gooseneck assembly is mounted for linear movement to actuate the nozzle onto the die parting line.

Abstract: A die casting system comprises a machine of the balanced, dual movement type wherein the part is cast and trimmed without any lateral movement. Both halves of the molds or dies are moved equal distances to and from the part plane. The machine incorporates a system of metal injection on the mold parting line with a runner-drain provision; provision for supporting the part at a plurality of points after the die opening; hydraulic fluid volumetric flow reduction; various nozzle configuration options and a heat transfer system for the dies. In addition, a part trimming machine is disclosed together with a cable transfer for moving the part from the casting machine to the trimming machine.

Abstract: A method and device for controlling the flow of molten metal of a hot chamber die casting machine from an outer surrounding melt crucible into the bore of a casting bushing which is located in the melt and which has a melt inlet opening disposed below the level of the melt in the crucible which is located upstream of a sprue runner leading to the mold cavity having a mold part maintained under closing pressure during the molding, includes a firing piston for moving a casting piston in the bore of the casting bushing so as to close the opening and to direct the melt into the mold cavity. After casting, the casting piston is moved backwardly to relieve the pressure on the mold slightly and the mold is partially opened. The casting position is locked against further movement, however, so as to prevent an inflow of the melt through the sprue runner to the mold immediately after casting.

Abstract: An apparatus for the casting of metals and other materials under pressure in which the molten metal is introduced into a cylinder which is pressurized by a piston through an intervening pneumatic cushion to drive the molten metal into the mold. When the mold is filled with the metal, the piston increases the pressure further so as to maintain the pressure during solidification. Advantageously, the cylinder from which the molten metal is driven, is connected by a further cylinder to a hot chamber in which the melt is prepared, the connection between the two cylinders being at the bottom thereof and the entire assembly being mounted on a tiltable frame.

Abstract: A gooseneck for a hot chamber die casting machine, which gooseneck includes a compression chamber having a pressure piston movably mounted therein with the compression chamber being in communication witha conical mouthpiece by way of transverse and vertical passages. The mouthpiece is arranged in a neck projecting from the gooseneck with the entire gooseneck being forged from a heat-resistant tool steel. The area of the casting container which includes the compression chamber and the vertical passage has in cross-section the form of two cylinders with parallel axes. A heating device may be provided for heating the projecting neck portion forming the mouthpiece of the gooseneck and a further heating construction may be provided for heating the injection nozzle to prevent the solidification of a melt therein.

Abstract: In a hot chamber method of pore-free die casting in which a reactive gas flushes non-reactive gas such as air from a die before a material is cast therein, the material displaces non-reactive gas from the gooseneck and nozzle through which the die is filled before the reactive gas flushes the die. The material then does not push non-reactive gas into the die as it fills the die. Apparatus for practicing the method comprises servo-control means for filling the gooseneck and nozzle with the material before the reactive gas flushes the die to displace non-reactive gas therefrom and then filling the die with the material after the reactive gas has flushed the die.

Abstract: In a hot chamber method of pore-free die casting, a gas which reacts with the cast material flushes air from a passage in a nozzle, sprue bushing, and at least a portion of a gooseneck through which the material fills the die cavity, as well as from the die cavity. The reactive gas replaces the air in the passage so that air is not forced into the die cavity by the material when it fills the die cavity. Air in the die cavity would form pores in the cast material. Hot chamber apparatus for practicing the method has a bore communicating with the passage for flushing the passage with the gas. A valve closes the bore when the material fills the die cavity so that the material only enters the die cavity. A heating element heats the valve to prevent the material from solidifying about the valve and thereby interfering with its operation.

Abstract: To move the die parts and cores into position for a casting operation, a plurality of pneumatic cylinders are mounted between two parallel plates of the head of a casting machine and arranged so that they each move a different one of a plurality of die parts and cores of a die from any of several angles, exerting primarily tension on the plates rather than torsion, with each cylinder including an internal locking mechanism having locking balls that drop into holding grooves to hold the piston of the hydraulic cylinder in position with sufficient strength to withstand the pressure of the molten metal applied to the die. To inject the molten metal into the die, a nozzle spool is moved in a straight line to communicate with the interior of the die between two die parts, the molten metal being fed to an annular recess around the spool by an injector and from the annular recess through openings in the spool into a central conduit that communicates with the interior of the die.

Abstract: In the method, a shot sleeve, for receiving a metered quantity of melt through an inlet or filling opening and connected to the mold cavity, has its volume continuously diminished in such a manner as to maintain a constant communication between the space above the melt in the shot sleeve and the mold cavity for escape of all the gas or air above the melt into the mold cavity before the opening of the shot sleeve into the mold cavity is completely closed by the advancing melt. This is effected, during the shot-pre-filling phase, by an accelerated motion of an injection piston from a rest position, at which the filling inlet to the shot sleeve is open, through the shot sleeve toward the mold cavity opening. As a result of the accelerated motion of the piston, the melt spreads over the melt engaging surface of the injection piston and the formation of a standing wave is prevented.